Fibers having improved dullness and products containing the same

ABSTRACT

Fibers having a reduced amount of glare are disclosed. Products made therefrom the fibers are also disclosed. Methods of making the fibers and products are further disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of provisional application Ser. No.60/403,889, filed Aug. 16, 2002, entitled “Fibers Having ImprovedDullness and Products Containing the Same”.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to fibers having a reduced amount ofglare, and products made therefrom.

2. Background of the Invention

There is a desire in the carpet industry for fibers having a reducedamount of glare. Carpets, such as carpets used in homes, recreationalvehicles, offices, and automobiles, may be exposed to one or more lightsources including, but not limited to, sunlight and artificial light.Carpet fibers reflect light and cause an undesirable amount of glare.

What is needed in the art is a fiber having a fiber design, whichminimizes the amount of light reflection transmission and glare. What isalso needed in the art is a carpet containing fibers, wherein the fibersproduce a minimum amount of glare when exposed to natural or artificiallight.

SUMMARY OF THE INVENTION

The present invention addresses some of the difficulties associated withminimizing the amount of glare in carpet fibers by the discovery ofnovel fibers, which minimize the amount of glare when exposed to naturalor artificial light. The fibers of the present invention possess fibercross-sections, which provide unique properties to the fibers andproducts made therefrom.

Accordingly, the present invention is directed to fibers having a uniquecross-section, which provides unique properties to the fiber including,but not limited to, a minimal amount of glare.

The present invention is also directed to a method of making fibershaving unique fiber cross-sections and products containing the same.

These and other features and advantages of the present invention willbecome apparent after a review of the following detailed description ofthe disclosed embodiments and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a fiber cross-section of an exemplary fiber of theproposed invention and the components of the fiber;

FIG. 2 depicts a fiber cross-section of an exemplary fiber of thepresent invention having a forked tri-lobal design;

FIG. 2A depicts features of a forked multi-lobal design relative to theorientation of lobes to one another;

FIG. 3A depicts a fiber cross-section of an exemplary fiber of thepresent invention having a serpentine tri-lobal design;

FIG. 3B depicts a fiber cross-section of an exemplary fiber of thepresent invention having an “elongated S” tri-lobal design;

FIG. 4A depicts a fiber cross-section of an exemplary forked tri-lobalfiber and its dimensions;

FIG. 4B depicts a fiber cross-section of an exemplary serpentinetri-lobal fiber and its dimensions;

FIG. 4C depicts a fiber cross-section of an exemplary elongated Stri-lobal fiber and its dimensions;

FIG. 5 depicts a capillary design for forming the exemplary forkedtri-lobal fiber shown in FIG. 2

FIG. 6 depicts a capillary design for forming the exemplary serpentinetri-lobal fiber shown in FIG. 3A; and

FIG. 7 depicts a capillary design for forming the exemplary elongated Stri-lobal fiber shown in FIG. 3B.

DETAILED DESCRIPTION OF THE INVENTION

To promote an understanding of the principles of the present invention,descriptions of specific embodiments of the invention follow andspecific language is used to describe the specific embodiments. It willnevertheless be understood that no limitation of the scope of theinvention is intended by the use of special languages. Alterations,further modifications, and such further applications of the principlesof the present invention discussed are contemplated as would normallyoccur to one ordinarily skilled in the art to which the inventionpertains.

The present invention is directed to fibers having unique fibercross-section configurations, wherein the fibers possess a minimumamount of glare and a maximum amount of dullness. As used herein, theterm “dullness” refers to the resistance of a fiber to reflect naturalor artificial tight. The present invention is further directed toproducts containing the above-mentioned fibers, such as carpet tiles andcarpet fabrics. The present invention is further directed to methods ofmaking the above-described fibers and products containing the same.

I. Fibers

The fibers of the present invention possess a fiber configuration, whichmaximizes the amount of dullness of the fiber. The properties andchemical composition of the fibers are discussed below.

A. Fiber Cross-Sectional Configuration

A number of ways may be used to describe the cross-sectionalconfiguration of the fibers of the present invention. One method ofdescribing the cross-sectional configuration of the fibers is byexamining the components of the fiber including the central axis, thefiber core, and the lobes of the fiber. As used herein, the term “lobe”refers to fiber extensions radiating from a fiber central core. Forexample, in FIG. 1, an exemplary fiber cross-sectional configuration 10is shown having a fiber central axis 101, a fiber central core 11 andthree symmetrical lobes 12. An inscribed circle 13 is used to designatecentral core 11 of fiber 10. As used throughout the description of thepresent invention, the lobes 12 of a given fiber comprise thecross-sectional area of the fiber outside of inscribed circle 13 (seeFIG. 1).

The fibers of the present invention may also be described in terms ofthe number of concave portions, the number of convex portions, and thenumber of inflection points along an outer perimeter of a given lobe ofthe fiber. As used herein, the term “concave portion” is used todescribe a portion of the outer perimeter of a lobal cross-section,which forms an arc of curvature wherein die radius of curvature for thearc points away from the fiber lobe. As used herein, the term “convexportion” is used to describe a portion of the outer perimeter of a lobalcross-section, which forms an arc of curvature wherein the radius of thearc points toward the fiber lobe. As used herein, the term “inflectionpoint” is used to describe an intersection between a concave portion anda convex portion of the outer perimeter. As shown in FIG. 1, concaveportion 14 extends from point 15 to inflection point 16 along an outerperimeter 17 of the fiber cross-sectional configuration. Convex portion18 extends from inflection point 16 along perimeter 17 to a secondinflection point 19.

The fibers of the present invention desirably comprise two or more lobesextending from and equally spaced along a central core of the fiber. Inone desired embodiment of the present invention, the fiber comprisesthree lobes extending from and equally spaced along a central fiberportion. In a further embodiment of the present invention, the fibercomprises four symmetrical lobes extending from and equally spaced alonga central portion of the fiber.

As used herein, the term “equally spaced” refers to the relativepositions of the two or more lobes within a 360° path. For example, fora fiber having two equally spaced lobes extending from a fiber centralcore, the lobes are separated from one another by an angle of about180°, desirably, 180°±10°, more desirably, 180°±5°, and even moredesirably 180°±1°. For a fiber having three equally spaced lobesextending from a fiber central core, the lobes are separated from oneanother by an angle of about 120°, desirably, 120°±10°, more desirably,120°±5°, and even more desirably, 120°±1°. For a fiber having fourequally spaced lobes extending from a fiber central core, the lobes areseparated from one another by an angle of about 90°, desirably, 90°±10°,more desirably, 90°±5°, and even more desirably, 90°±1°. For more thanfour lobes, the lobes are desirably equally spaced from one anotheraround a fiber central core by (360°/n), where n is the number of lobes.

The fibers of the present invention possess exceptional dullnessproperties (i.e., reduced glare) due to the unique structure of thelobes extending from the fiber central core. A cross-sectionalexamination of each lobe shows a combination of concave portions, convexportions, and inflection points along an outer perimeter of the lobalcross-sectional area. In one desired embodiment of tile presentinvention, each lobe has a substantially similar lobal cross-sectionalconfiguration comprising at least three concave portions, at least toconvex portions, and at least four inflection points along an outerperiphery of the lobal cross-sectional area. In another desiredembodiment of the present invention, each lobe has a substantiallysimilar lobal cross-sectional configuration comprising at least threeconcave portions, at least three convex portions, and at least fiveinflection points along an outer perimeter of the lobal cross-sectionalarea. As used herein, the term “substantially similar lobalcross-sectional configuration” is used to describe lobal cross-sectionalconfigurations, which appear to have an identical combination andsequence of concave portions, convex portions, and inflection pointsalong an outer periphery of the lobal cross-sectional area such that ifone lobal cross-sectional configuration is placed on top of anotherlobal cross-sectional configuration, the outer perimeters of bothcross-sections would trace each other. It should be noted that eachindividual lobe of a given fiber may have one or more imperfections inthe cross-sectional configuration. Such imperfections may result inslight differences between adjacent lobes; however, such fibers are alsowithin the scope of the present invention.

In one desired embodiment of the present invention, each lobe containsthree concave portions, two convex portions, and four inflection pointsalong an outer periphery of the fiber cross-sectional area. In thisdesired embodiment, the combination of concave portions, convexportions, and inflection points along the outer perimeter of each lobalcross-sectional area forms a symmetrical pathway such that alobe-dissecting line extending from a fiber central axis through acentral portion of the lobe dissects the lobe into two substantiallyidentical lobal portions on each side of the lobe-dissecting line.

One exemplar) fiber of the present invention having such a symmetricalpathway is shown in FIG. 2. The fiber shown in FIG. 2 has what isreferred to herein as a “forked tri-lobal” fiber configuration. Each ofthe lobes 21 of fiber 20 has a substantially identical cross-sectionalconfiguration, which includes concave portions 22A through 22C, convexportions 23A through 23B, and inflection points 24A through 24D. Asshown in FIG. 2, the forked tri-lobal fiber configuration issubstantially free of any flat surfaces along an outer periphery of thefiber cross-section. In other words, the forked tri-lobal fibercross-section comprises only concave portions, convex portions andinflection points. In particular, each lobe 21 comprises the followingsequence of components: a first concave portion (22A), a firstinflection point (24A), a first convex portion (23A), a secondinflection point (24B), a second concave portion (23A), a thirdinflection point (24C), a second convex portion (23B), a fourthinflection point (24D), and a third concave portion (22C). The absenceof flat surfaces along an outer periphery of the forked tri-lobal fiberof the present invention enhances the dullness of the fiber when exposedto natural or artificial light.

It should be understood that other forked multi-lobal fibers are withinthe scope of the present invention. For example, a forked tetra-lobalfiber of die present invention comprises four equally spaced lobes alonga central fiber core, wherein each lobe has a lobal cross-sectionalconfiguration substantially similar to lobes 21 shown in FIG. 2.

In the forked multi-lobal fibers of the present invention, the concaveportions, convex portions, and inflection points form a symmetricalouter periphery 25, which is symmetrical along a line 26 extending fromcentral axis 27 of fiber 20 through a central portion of lobe 21 asshown in FIG. 2. Furthermore, it should be understood that it isdesirable for each lobe 21 to be equally spaced from one another alongcentral axis 27. In other words, for a tri-lobal fiber of the presentinvention, it is desirable for the angle between line 26 and line 28 asshown in FIG. 2 to be about 120°. For tetra-lobal fibers of the presentinvention, it is desirable for the angle between each lobe to be about90°.

A further desirable characteristic of the forked multi-lobal fibers ofthe present invention is the orientation of the lobe tips to oneanother. As shown in FIG. 2A, the maximum distance between adjacentlobes 211 and 212 is along line 213 between point 291 on lobe 211 andpoint 292 on adjacent lobe 212. Desirably, the maximum distance betweenadjacent lobes in the forked multi-lobal fibers of the present inventionis measurable at a location near the maximum width of each lobe (e.g.,point 291 on lobe 211 and point 292 on adjacent lobe 212 are bothlocated on their respective lobe at about a maximum width of each lobe,the maximum width of each lobe being designated by dash lines 293 and294). Also, dotted lines 214 represent lines extending from concaveportions 215 between adjacent lobes. Dotted lines 214 extend frominflection points 216. In the forked multi-lobal fibers of the presentinvention, dotted lines 214 extending from inflection points 216 betweenadjacent lobes are desirably parallel to one another or divergentrelative to one another (i.e., the lines do not cross one another). Thisparticularly characteristic of the forked multi-lobal fibers of thepresent invention also provides improved dullness (i.e., reduced glare).

In a further desired embodiment of the present invention, each lobecontains at least three concave portions, at least three convexportions, and at least five inflection points along an outer peripheryof the fiber cross-sectional area. In this desired embodiment, thecombination of concave portions, convex portions, and inflection pointsalong the outer perimeter of each lobal cross-sectional area forms apathway such that a lobe-dissecting line extending outward from a fibercentral axis through the lobe moves in a serpentine-like pathway to atip of the lobe. Further, the tip of the lobe is off-center from astraight line extending outward from a fiber central axis in adirection, which dissects a portion of lobe adjacent to the fibercentral core.

One exemplary fiber of the present invention having such aserpentine-like stricture is shown in FIG. 3A. The fiber shown in FIG.3A has what is referred to herein as a “serpentine tri-lobal” fibercross-sectional configuration. Each lobe 31 of the serpentine tri-lobalfiber configuration 30 comprises concave portions 32A through 32C,convex portions 33A through 33C, and inflection points 34A through 34E.Like the forked tri-lobal fiber cross-sectional configuration, theserpentine tri-lobal fiber cross-sectional configuration issubstantially free of flat surfaces along outer periphery 35 of lobes31. Further, like the forked multi-lobal fibers described above,serpentine multi-lobal fibers having two or more substantially similarserpentine lobes extending from a central fiber core are also within thescope of the present invention.

Each lobe of a serpentine multi-lobal fiber of the present inventionpossesses a unique combination of concave portions, convex portions, andinflection points alone an outer perimeter of the lobal cross-section.In one embodiment of the present invention (as shown in FIG. 3A), eachlobe of the serpentine multi-lobal fiber has the following sequence ofcomponents, starting from a left-hand side of the lobe when observing across-sectional configuration of the lobe: a first convex portion (33A),a first inflection point (34A), a first concave portion (32A), a secondinflection point (34B), a second convex portion (33B), a thirdinflection point (34C), a second concave portion (32B), a fourthinflection point (34D), a third convex portion (33C), a fifth inflectionpoint (34E), and a third concave portion (32C). The serpentine designmay further include additional concave portions, convex portions, andinflection points as long as the serpentine-like design remains. Aninteresting characteristic of the serpentine design is that thethickness of the lobe either remains the same or narrows as the lobeextends from a central fiber core. In one embodiment of the presentinvention, the thickness of each lobe gradually narrows in thickness asthe lobe gets further away from a fiber center core. As shown in FIG.3A, a lobe-dissecting line 39 extending outward from fiber central axis38 through lobe 31 moves in a serpentine-like pathway to tip 36 of lobe31. The tip 36 of each lobe 31 is off-center from a line 37, whichextends outward from central fiber axis 38 through a central portion oflobe 31.

In yet a further desired embodiment of the present invention, each lobecontains at least three concave portions, at least three convexportions, and at least four inflection points along an outer peripheryof the fiber cross-sectional area. In this desired embodiment, thecombination of concave portions, convex portions, and inflection pointsalong the outer perimeter of each lobal cross-sectional area forms apathway such that a lobe-dissecting line extending outward from a fibercentral axis through the lobe moves in an S-shaped pathway to a tip ofthe lobe. Further, the tip of the lobe is off-center from a straightline extending outward from a fiber central axis in a direction, whichdissects a portion of lobe adjacent to the fiber central core.

One exemplar, fiber of the present invention having lobes with such aS-shaped structure is shown in FIG. 3B. The fiber shown in FIG. 3B haswhat is referred to herein as an “elongated S” tri-lobal fibercross-sectional configuration. Each lobe 310 of the elongated Stri-lobal fiber configuration 300 comprises concave portions 320Athrough 320C, convex portions 330A through 330C, and inflection points340A through 340D. Unlike the forked tri-lobal fiber cross-sectionalconfiguration and the serpentine tri-lobal fiber cross-sectionalconfiguration described above, the elongated S tri-lobal fiberconfiguration may have a substantially flat surface 378 along outerperiphery 350 of lobes 310. Desirably, substantially flat surface 378along outer periphery 350 of lobes 310 has a length of from about 130 μmto about 300 μm, more desirably, from about 180 μm to about 280 μm. Itshould be noted that the portion of the fiber lobe along surface 378 asshown in FIG. 3B may have a concave portion and one or more inflectionpoints therein. In some cases, the fiber lobe along surface 378 doescontain a concave portion and two inflection points. Further, like theforked multi-lobal fibers described above, elongated S tri-lobal fibershaving two or more substantially similar elongated S lobes extendingfrom a central fiber core are also within the scope of the presentinvention.

Each lobe of an elongated S multi-lobal fiber of the present inventionpossesses a unique combination of concave portions, convex portions, andinflection points along an outer perimeter of the lobal cross-section.In one embodiment of the present invention (as shown in FIG. 3B), eachlobe of the elongated S multi-lobal fiber has the following sequence ofcomponents, starting from a left-hand side of the lobe when observing across-sectional configuration of the lobe: a first concave portion(320A), a first inflection point (340A), a first convex portion (330A),a substantially flat section (378), a second convex portion (330B), asecond inflection point (340B), a second concave portion (320B), a thirdinflection point (340C), a third convex portion (330C), a fourthinflection point (340D), and a third concave portion (320C). Theelongated S design may further include additional concave portions,convex portions, and inflection points as long as the elongated S designremains.

In a further embodiment of the present invention, substantially flatsection (378) contains a concave portion and two inflection points. Theresulting elongated S multi-lobal fiber contains lobes, wherein eachlobe of the fiber has the following sequence of components, startingfrom a left-hand side of the lobe when observing a cross-sectionalconfiguration of the lobe: a first concave portion (320A), a firstinflection point (340A), a first convex portion (330A), a secondinflection point (not shown), a second concave portion (not shown), athird inflection point (not shown), a second convex portion (330B), afourth inflection point (340B), a third concave portion (320B), a fifthinflection point (340C), a third convex portion (330C), a sixthinflection point (340D), and a fourth concave portion (320C).

An interesting characteristic of the elongated S design is that thethickness of the lobe either remains substantially the same as the lobeextends from a central fiber core. In one embodiment of the presentinvention, the thickness of each lobe gradually narrows in thickness asthe lobe approaches the tip of the lobe, but then gradually expands(i.e., widens) to form a bulb on the tip of the lobe. As shown in FIG.3B, a lobe-dissecting line 390 extending outward from fiber central axis380 through lobe 310 moves in an S-shaped pathway to tip 360 of lobe310. The tip 360 of each lobe 310 is off-center from a line 370, whichextends outward from central fiber axis 380 through a central portion oflobe 310.

B. Fiber Dimensions

The fibers of the present invention may have dimensions, which varydepending on a number of factors including, but not limited to, fibermaterials such as polymer type and additives; processing conditions suchas spring temperature, melt viscosity of the polymer, and quench medium;and end use. Typically, the fibers of the present invention havedimensions as shown in Table 1 below. TABLE 1 Fiber Dimensions FiberDimension Range Desired Range Fiber Core Thickness about 10 to aboutabout 15 to about 30 μm 24 μm Fiber Width about 50 to about about 80 toabout 120 μm 100 μm Average Thickness of about 8 to about about 8 toabout Lobe Component 50 μm 35 μm Proximate to Fiber Core Length of Lobeabout 15 to about about 21 to about Component 55 μm 48 μm

Each of the fiber measurements given above in Table 1 may be fullyunderstood with reference to FIGS. 4A, 4B and 4C. As used herein, “fibercore thickness” Is used to refer to the diameter of an inscribed circle43 within fiber cross-sectional areas 41, 42 and 420 as shown in FIGS.4A, 4B and 4C respectively. As used herein, “fiber width” is used torefer to the diameter of a circumscribed circle 430 surrounding fibercross-sectional areas 41, 42 and 420 as shown in FIGS. 4A, 4B and 4Crespectively. As used herein. “average thickness of lobe componentproximate to fiber core” refers to a length represented by lines 440,480 and 481 as shown in FIGS. 4A, 4B and 4C respectively, wherein eachline is perpendicular to lobe-dissecting line 49. As used herein,“length of lobe” refers to a length extending from central fiber axis 46to line 47 in FIG. 4A, line 471 in 4B, and line 482 in 4C.

Desired fiber dimensions for forked multi-lobal fibers of the presentinvention are shown in Table 2 below. As used herein, “minimum thicknessof lobe component” (t_(min)) refers to a minimum thickness as shown bylines 44, 45 and 483 in FIGS. 4A, 4B and 4C respectively, whichrepresents a length that is perpendicular to a lobe-dissecting line 49extending from fiber central axis 46 through a central portion of alobe. As used herein, “maximum thickness of lobe component” (t_(max))refers to a maximum length represented by lines 47, 48 and 484 in FIGS.4A, 4B and 4C respectively, which is also perpendicular tolobe-dissecting line 49. TABLE 2 Fiber Dimensions For Forked Multi-LobalFibers Fiber Dimension Desired Range Fiber Core Thickness about 15.0 μmto about 18.0 μm Minimum Thickness of Lobe about 9.0 μm to about 15.0 μmComponent, t_(min) Maximum Thickness of Lobe about 23.0 μm to about 35.0μm Component, t_(max) Length of Lobe Component about 21.5 μm to about33.5 μm

Desired fiber dimensions for serpentine multi-lobal fibers of thepresent invention are shown in Table 3 below. TABLE 3 Fiber DimensionsFor Serpentine Multi-Lobal Fibers Fiber Dimension Desired Range FiberCore Thickness about 18 μm to about 22 μm Minimum Thickness of Lobeabout 8 μm to about 12 μm Component, t_(min) Maximum Thickness of Lobeabout 13 μm to about 19 μm Component, t_(max) Length of Lobe Componentabout 43 μm to about 48 μm

Desired fiber dimensions for elongated S multi-lobal fibers of thepresent invention are shown in Table 4 below. TABLE 4 Fiber DimensionsFor Elongated S Multi-Lobal Fibers Fiber Dimension Desired Range FiberCore Thickness about 19 μm to about 24 μm Minimum Thickness of Lobeabout 13 μm to about 18 μm Component, t_(min) Maximum Thickness of Lobeabout 13 μm to about 18 μm Component, t_(max) Length of Lobe Componentabout 30 μm to about 40 μm

The fibers of the present invention may also be characterized by theirmodification ratio. As used herein, the term “modification ratio” (MR)refers to the ratio of (a) the radius of a circle, which circumscribesthe filament cross-sectional area to (b) the radius of the largestcircle, which may be inscribed within the filament cross-section.Desirably, the modification ratio of the fibers of the present inventionis greater than about 4.0, more desirably, greater than about 4.1.

The fibers of the present invention may be further characterized bytheir denier per filament (dpf). Denier per filament is defined as theweight in grams of a single filament with a length of 9000 meters.Desirably, the fibers of the present invention have a denier perfilament ranging from about 3 to about 75 dpf. More desirably, thefibers of the present invention have a denier per filament ranging fromabout 10 to about 38 dpf. Even more desirably, the fibers of the presentinvention have a denier per filament ranging from about 13 to about 19dpf.

C. Fiber Composition

The fibers of the present invention may be prepared from a variety ofthermoplastic polymeric materials. Suitable thermoplastic polymericmaterials include, but are not limited to, polyamides, polyesters,polyolefins, or a combination thereof. Desirably, the fibers of thepresent invention comprise one or more polyamides selected from nylon 6,nylon 6/6, nylon 6/9, nylon 6/10, nylon 6/12, nylon 11, nylon 12,copolymers thereof and mixtures thereof. More desirably, the fibers ofthe present invention comprise monocomponent fibers comprising a singlepolyamide selected from nylon 6 and nylon 6/6. Suitable polyestersinclude, but are not limited to, polyethylene terephthalate.

The fibers of the present invention may contain one or more additivesblended into the thermoplastic polymeric material. Suitable additivesinclude, but are not limited to, lubricants, nucleating agents,antioxidants, ultraviolet light stabilizers, pigments, dyes, antistaticagents, soil resists, stain resists, antimicrobial agents, and flameretardants. When present, the one or more additives are present in anamount of up to about 15 weight percent (wt %) based on a total weightof the thermoplastic polymeric material.

II. Method of Making Fibers

The present invention is further directed to methods of making theabove-described fibers. Conventional melt-extension processes may beused to produce the fibers of the present invention using capillaryconfigurations, which result in fibers having a desired cross-sectionalconfiguration as described above. Suitable capillary configurationsinclude, butt are not limited to, the capillary configurations as shownin FIGS. 5, 6 and 7.

In one method of the present invention, polymer is fed into all extruderin the form of chips or granules. The polymer is melted and directed viajacketed DOWTHERM® (Dow Chemical, Midland Mich.) heated polymerdistribution lines to a spinning head. The polymer melt is then meteredby a high efficiency gear pump to a spin pack assembly and extrudedthrough a spinnerette with capillaries having a capillary configurationsuch as those shown in FIGS. 5, 6 and 7. The polymer is extruded throughthe capillary of the spinnerette plate to form a fiber having a desiredfiber cross-sectional configuration as described above.

Spinnerette plates used in the method of the present invention typicallyhave from about 5 to about 300 openings in the form of capillaries asdescribed above, desirably from about 10 to about 200 openings. Theextruded fibers are drawn and quenched, for example, with air in orderto orient and solidify the fibers.

The fibers may then be treated with a finish comprising a lubricatingoil or mixture of oils and antistatic agents. The fibers are thentypically combined to form a yarn bundle, which is then wound on asuitable package.

In a subsequent step, the yarn may be drawn and texturized to form abulked continuous filament (BCF) yarn suitable for tufting into carpets.One desired technique involves combining the extruded or as-spunfilaments into a yarn, then drawing, texturizing and winding a package,all in a single step. This one-step method of making BCF is referred toin the trade as spin-draw-texturing.

The fibers of the present invention may be made using any of the methodsdisclosed in U.S. Pat. Nos. 5,263,845 and 5,387,469, the disclosure ofboth of which is herein incorporated by reference.

Fibers of die present invention for use in carpet manufacturingtypically have fiber deniers (denier being the weight in grams of asingle filament with a length of 9000 meters) in the range of about 3 to75 denier/filament (dpf). Desirably, the denier range for carpet fibersis from about 6 to 35 dpf. The BCF yarns may proceed through variousprocessing steps well known to those of ordinary skilled in the art. Thefibers of the present invention are particularly useful in themanufacture of carpets for floor covering applications.

To produce carpets for floor covering applications, the BCF yarns aregenerally tufted into a pliable primary backing. Primary backingmaterials may include, but are not limited to, conventional woven jute,woven polypropylene, cellulosic nonwovens and nonwovens of nylon,polyester, and polypropylene. The primary backing may then be coatedwith a suitable latex material such as a conventional styrene-butadienelatex, a vinylidene chloride polymer, or a vinyl chloride-vinylidenechloride copolymers. It is common practice to use fillers such ascalcium carbonate to reduce latex costs. The final step is to apply asecondary backing, generally a woven jute or woven synthetic such aspolypropylene onto the primary backing.

In one desired embodiment of the present invention, the method comprisesforming forked tri-lobal fibers having a fiber cross-sectionalconfiguration as shown in FIG. 2 by extruding polymer melt through acapillary having a design as shown in FIG. 5. Although the capillarydimensions are not limited in any way (other than to form the forkedtri-lobal design), desirably, the capillary has the dimensions as shownin Table 5 below, wherein A_(orf) represents the total area of thecapillary, P_(orf) represents the length of the perimeter of thecapillary, and D_(orf) represents the diameter of a circle, whichcompletely surrounds the capillary. TABLE 5 Capillary Dimensions ForForming Exemplary Forked Tri- Lobal Fibers Capillary Data DimensionDesired Range A_(orf) about 0.31 to about 0.35 mm P_(orf) about 7.42 toabout 7.50 mm D_(orf) about 1.53 to about 1.60 mm

In one desired embodiment, the capillary dimensions are: A_(orf) is 0.33mm²; P_(orf) is 7.46 mm; and D_(orf) is 1.58 mm.

The resulting fibers from the method described above using the capillarydesign as shown in FIG. 5 and the dimensions as shown in Table 5desirably have the following fiber dimensions as shown in Table 6,wherein A_(fib) represents the total area of the fiber, P_(fib)represents the length of the perimeter of the fiber, and D_(fib)represents the diameter of a circle, which completely surrounds thefiber. TABLE 6 Fiber Dimensions For Exemplary Forked Tri-Lobal FibersFiber Data Dimension Desired Range A_(fib) about 0.0012 to about 0.0014mm² P_(fib) about 0.2285 to about 0.2362 mm D_(fib) about 0.046 to about0.060 mmIn one desired embodiment, the resulting fiber dimensions are: A_(fib)is 0.0013 mm²; P_(fib) is 0.2324 mm; and D_(fib) is 0.053 mm.

In a further desired embodiment of the present invention, the methodcomprises forming serpentine tri-lobal fibers having a fibercross-sectional configuration as shown in FIG. 3A by extruding polymermelt through a capillary having a design as shown in FIG. 6. Desirably,the capillary has the dimensions as shown in Table 7 below. TABLE 7Capillary Dimensions For Forming Exemplary Serpentine Tri- Lobal FibersCapillary Data Dimension Desired Range A_(orf) about 0.24 to about 0.28mm² P_(orf) about 5.79 to about 5.89 mm D_(orf) about 1.53 to about 1.63mmIn one desired embodiment, the capillary dimensions are: A_(orf) is 0.26mm², P_(orf) is 5.84 mm; and D_(orf) is 1.58 mm.

The resulting fibers from the method described above using the capillarydesign as shown in FIG. 6 and the dimensions as shown in Table 7desirably have the following fiber dimensions as shown in Table 8. TABLE8 Fiber Dimensions For Exemplary Serpentine Tri-Lobal Fibers Fiber DataDimension Desired Range A_(fib) about 0.0016 to about 0.0018 mm² P_(fib)about 0.3027 to about 0.3131 mm D_(fib) about 0.087 to about 0.090 mmIn one desired embodiment, the fiber dimensions are: A_(fib) is 0.0017mm²; P_(fib) is 0.3079 mm; and D_(fib) is 0.088 mm.

In yet a further desired embodiment of the present invention, the methodcomprises forming elongated S tri-lobal fibers having a fibercross-sectional configuration as shown in FIG. 3B by extruding polymermelt through a capillary having a design as shown in FIG. 7. Desirably,the capillary has the dimensions as shown in Table 9 below. TABLE 9Capillary Dimensions For Forming Exemplary Elongated S Tri-Lobal FibersCapillary Data Dimension Range A_(orf) 0.20 to 0.30 mm² P_(orf) 4.85 to5.30 mm D_(orf) 1.45 to 1.70 mmIn one desired embodiment, the capillary dimensions are: A_(orf) is 0.24mm²; P_(orf) is 5.15 mm; and D_(orf) is 1.58 mm.

The resulting fibers from the method described above using the capillarydesign as shown in FIG. 7 and the dimensions as shown n Table 9desirable have the following fiber dimensions as shown in Table 10.TABLE 10 Fiber Dimensions For Exemplary Elongated S Tri-Lobal FibersFiber Data Dimension Desired Range A_(fib) about 0.0017 to about 0.0021mm² P_(fib) about 0.2742 to about 0.2797 mm D_(fib) about 0.088 to about0.091 mmIn one desired embodiment, the fiber dimensions are. A_(fib) is 0.0019mm²; P_(fib) is 0.2770 mm; and D_(fib) is 0.089 mm.

The present invention is further illustrated by the following examples,which are not to be construed in any way as imposing limitations uponthe scope thereof. On the contrary, it is to be clearly understood thatresort may be had to various other embodiments, modifications, andequivalents thereof which, after reading the description herein, maysuggest themselves to those skilled in the art without departing fromthe spirit of the present invention and/or the scope of the appendedclams.

EXAMPLE 1 Preparation of a Nylon Forked Tri-Lobal Fiber and YarnContaining the Same

Nylon 6 filaments were spun using the capillary design as shown in FIG.5. Each spinnerette had 12 capillaries of the specific design with thefollowing dimensions:

-   -   A_(orf) is 0.3307 mm²;    -   P_(orf) is 7.4607 mm; and    -   D_(orf) is 1.5760 mm

The angle between lobe-forming portions in the capillary design was120°.

The nylon 6 polymer (relative viscosity, RV=2.7) was a bright polymerand did not contain any delusterant. The polymer temperature wascontrolled at the pump block at about 265° C.±0.1° C. and the spinningthroughput was 253 g/min per spinnerette.

The molten fibers were quenched in a chimney using 80 ft/min air forcooling the fibers. The filaments were pulled by a feed roll rotating ata surface speed of 865 m/min through the quench zone and coated with alubricant for drawing and crimping.

The yarns were combined and drawn at 1600 m/min and crimped by a processsimilar to that described in U.S. Pat. No. 4,095,317 to form a 1100denier 60 filament yarn.

The spun, drawn, and crimped yarns (BCF) were cable-twisted to a 3.5turns per inch (tpi) on a cable twister and heat-set on a Superbaheat-setting machine at standard conditions for nylon 6 BCF yarns. Theyarns were then tufted into a 32 oz yd², {fraction (3/16)} gauge cutpile carpet construction.

The carpet was rated for dullness by an observer panel. The carpet waspositioned on the floor and observed for dullness in full sunlight at anangle of about 30° (i.e., the angle of the incoming sunlight to thefloor was about 30°). The observer panel rated the carpet “superior” fordullness.

EXAMPLE 2 Preparation of a Nylon Serpentine Tri-Lobal Fiber and YarnContaining the Same

Nylon 6 filaments were prepared as described in Example 1 above except acapillary design as shown in FIG. 6 was used. A carpet made therefromwas rated for dullness as described in Example 1. The observer panelrated the carpet “superior” for dullness.

EXAMPLE 3 Preparation of a Nylon Elongated S Tri-lobal Fiber and YarnContaining the Same

Nylon 6 filaments were prepared as described in Example 1 above except acapillary design as shown in FIG. 7 was used. A carpet made therefromwas rated for dullness as described in Example 1. The observer panelrated the carpet “superior” for dullness.

While the specification has been described in detail with respect tospecific embodiments thereof, it will be appreciated that those skilledin the art, upon attaining an understanding of the foregoing, mayreadily conceive of alterations to, variations of, and equivalents tothese embodiments. Accordingly, the scope of the present inventionshould be assessed as that of the appended claims and any equivalentsthereto.

1-27. (canceled)
 28. A method of making a fiber comprising: meltextruding a polymer through a capillary having lobe-forming extensionsextending from a central portion of the capillary; drawing the extrudedpolymer to form a drawn fiber; quenching the drawn fiber to form asolidified resulting fiber; wherein the resulting fiber has across-sectional configuration such that the resulting fiber contains twoor more lobes extending from a central core, wherein the two or morelobes are equally spaced about an outer periphery of the central core;wherein each lobe has a substantially similar lobal cross-sectionalconfiguration comprising at least three concave portions, at least twoconvex portions, and at least four inflection points along an outerperimeter of each lobal cross-sectional area.
 29. The method of claim 28wherein the capillary has a capillary profile as shown in FIG.
 5. 30.The method of claim 28, wherein the capillary has a capillary profile asshown in FIG.
 6. 31. The method of claim 28, wherein the capillary has acapillary profile as shown in FIG.
 7. 32. A method of making a fibercomprising: melt extruding a polymer through a capillary havinglobe-forming extensions extending from a central portion of thecapillary; drawing the extruded polymer to form a drawn fiber; quenchingthe drawn fiber to form a solidified resulting fiber; wherein theresulting fiber has a cross-sectional configuration such that theresulting fiber contains two or more lobes extending from a centralcore, wherein the two or more lobes are equally spaced about an outerperiphery of the central core; wherein each lobe has a substantiallysimilar lobal cross-sectional configuration comprising at least threeconcave portions, at least two convex portions, and at least fourinflection points along an outer perimeter of each lobal cross-sectionalarea, and wherein a maximum distance between adjacent lobes is locatedbetween adjacent areas of maximum width of each of said adjacent lobes.33. The method of claim 32, wherein the capillary has a capillaryprofile as shown in FIG. 5.